Disposable aromatic barbecue enhancer

ABSTRACT

A disposable aromatic barbecue enhancer includes a foil housing formed in a generally cylindrical shape and defining an interior cavity. A combustible aromatic mixture is compacted within the interior cavity and a plurality of vent apertures are formed in the upper surface of the foil housing. In a fabrication method for the enhancer, a cylindrical receptacle supports a pair of extendable side pins and an extendable bottom pin beneath a movable piston. A plurality of pointed elements are supported within the cavity of the receptacle. A malleable incombustible sheet of foil material is initially placed overlying the receptacle and is formed by extrusion into the receptacle into a cup-like element. Thereafter, the combustible aromatic mixture is deposited therein. The mixture is compressed within the foil material and the foil is formed into a housing enclosure having the vent apertures pierced therein.

FIELD OF THE INVENTION

This invention relates generally to barbecue cooking units and particularly to those utilizing gas heating elements.

BACKGROUND OF THE INVENTION

Perhaps one of the most pervasive outdoor appliances in use today is that generally known as an outdoor barbecue or grill. The designs and structures of such barbecue grills have varied substantially as practitioners have sought to meet consumer needs. However, all such barbecue grills generally include a housing defining an interior cavity within which one or more tiers of grills are supported. At the bottom portion of the housing a heating apparatus is provided with the object being to create sufficient heat to cook the food articles placed upon the upper grill tiers.

Originally, such grills utilize a disposable fuel such as charcoal brochettes which were consumed during the cooking process producing ashes which were later discarded. To enhance the flavor and aroma of the cooking food in such barbecue grills, consumers often supplemented the burning charcoal brochettes with various aromatic wood chips and similar material such as the ever popular mesquite wood or the like.

As the use of outdoor cooking grills became more popular, manufacturers developed gas powered cooking grills in which the original charcoal brochette cooking elements were replaced by a group of gas burners and a layer of noncombustible heating materials such as various stones or rock. The object in such gas grills is to utilize the burner as the basic heat source while providing a generally even heat due to the heating action of the burner upon the stones or rock layer. Gas grills quickly became popular because of the avoidance of disposing of messy ash material as was the case in charcoal brochette heated barbecue units. In addition, consumers enjoyed the convenience of gas barbecue grills which did not provide the extensive delay associated with charcoal brochette barbecue units.

As the consumer began switching to the economy and convenience of gas fired barbecue grills, many consumers missed the fragrance of the conventional consumable fuel-type grills. In addition, the use of supplemental aromatic wood chips and the like in such gas grills produces a problem in disposing of the residue and ash. Thus, consumers enjoyed the convenience of gas grills but missed the fragrance and aroma of consumable fuel grill devices. To address this need, practitioners in the art developed several types of aromatic wood canisters intended to be used in gas-powered grills. In general, these provide noncombustible containers within which a quantity of aromatic wood chips and the like are housed. The object is to place the canister on the lower heated rock layer of the gas grill and rely upon the canister to retain the ash produced as the aromatic wood is slowly burned. Such devices have been provided in both reusable and refillable species as well as disposable design.

For example, U.S. Pat. No. 4,779,525 issued to Gaines sets 15 forth a SMOKE GENERATING DEVICE for use in a barbecue or the like is disclosed comprising a smoke producing material, such as wood chips, enclosed in a noncombustible perforated container. The perforations are kept covered by a perforation cover until use so as to prevent leakage of the smoke producing materials from the container and to prevent the loss of moisture and volatile aromatic oils from the smoke producing material. This cover is preferably constructed of a combustible material so that when heated in a barbecue, it will ignite and burn off to expose the perforations, through which the smoke can then escape to flavor the food.

U.S. Pat. No. 5,048,406 issued to Cofer sets forth a DISPOSABLE/REFILLABLE SMOKE CARTRIDGE FOR GAS BARBECUE GRILLS including a single unit, ready to use device for flavoring food by smoking on a barbecue grill using gas or other fuels having a cartridge containing small pieces of one of the aromatic woods, such as Hickory or Mesquite, etc., or any combination thereof. The package can contain draft vent perforations to allow enough air to flow in to promote charring without allowing ignition, and smoke to flow directably out. In use, the package is placed directly on the gas heated lava rocks, burning charcoal, or other fuel. When the process is complete, the cooled package is disposed along with other household refuse, or it can be saved for recycling. Multiple cartridges can be made available in multi-cartridge carriers and more than one cartridge can be used simultaneously or sequentially. The cartridges can be refilled, if desired.

While the foregoing designed prior art devices have provided 20 some limited capability for enhancing the aroma of gas powered barbecue grills, they tend to be expensive and of limited effectiveness. In particular, the refillable types of such devices are often messy and have been generally rejected by the consumer.

There remains, therefore, a continuing need in the art for an effective, inexpensive and easy to use disposable aromatic barbecue enhancer which provides the aromatic and flavor benefit of consumable fuel barbecue grills without the attendant mess.

SUMMARY OF THE INVENTION

Accordingly, it is a general object of the present invention to provide an improved aromatic barbecue enhancer. It is a more particular object of the present invention to provide an improved aromatic barbecue enhancer which is disposable and which is inexpensive to manufacture.

In accordance with the present invention, there is provided for use in a cooking grill or the like, a disposable enhancer comprises: an incombustible malleable sheet formed into a closed housing defining an interior cavity, a plurality of vent apertures, and a crimped closure surface; and an aromatic combustible particulate mixture received and compacted within the interior cavity.

BRIEF DESCRIPTION OF THE DRAWINGS

The features of the present invention, which are believed to be novel, are set forth with particularity in the appended claims. The invention, together with further objects and advantages thereof, may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in the several figures of which like reference numerals identify like elements and in which:

FIG. 1 sets forth a perspective view of a typical outdoor barbecue grill utilizing the present invention disposable aromatic barbecue enhancer;

FIG. 2 sets forth a perspective view of a disposable aromatic barbecue enhancer constructed in accordance with the present invention;

FIGS. 3 and 4 set forth section views of the present invention disposable aromatic barbecue enhancer taken along section lines 3-3 in FIG. 2 and showing the enhancer prior to and following combustion respectively;

FIG. 5 sets forth a perspective diagrammatic view of an apparatus for manufacturing the present invention disposable aromatic barbecue enhancer;

FIGS. 6A through 6G taken together set forth simplified diagrams describing a method of manufacturing the present invention disposable aromatic barbecue enhancer.

DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

FIG. 1 sets forth a perspective view of a conventional gas fire barbecue grill generally referenced by numeral 10. In accordance with conventional fabrication techniques, grill 10 includes a metal housing 11 supporting a hingedly coupled metal cover 12. Housing 11 defines an interior cavity 13 within which a lower grate 14 is received and supports a rock layer 15. A burner 14 also constructed in accordance with conventional fabrication techniques is supported beneath grate 14 and is coupled to a source of natural gas or the like (not shown). Grill 10 further includes a pair of cooking grates 16 and 17 supported above rock layer 15. In the position shown in FIG. 1, cooking grate 17 is pivoted in the direction indicated by arrow 18 to provide access to rock layer 15.

A barbecue enhancer constructed in accordance with the present invention and generally referenced by numeral 20 is placed upon rock layer 15 at a convenient spot afterwhich cooking grate 17 is returned to its normal position in a generally planar relationship with cooking grate 16. During the heating process and while the food articles are being cooked upon cooking grate 16, barbecue enhancer 20 produces an aromatic smoke stream 21 which, under normal cooking conditions, fills the cooking enclosure formed by housing 11 and cover 12 when closed. Thus, during the cooking process, the heat provided by burner 14 cooks the food articles upon cooking grates 16 and 17 while also supporting combustion of the aromatic combustible materials within barbecue enhancer 20 to provide an aromatic and flavorizing smoke which greatly increases the flavor and appeal of the food articles cooked within grill 10.

FIG. 2 sets forth a perspective view of barbecue enhancer 20. Enhancer 20 includes a generally cylindrical foil housing 22 preferably formed in the manner set forth below and defining an upper surface 23 and a cylindrical side surface 25. In its preferred form, foil housing 22 comprises a single sheet of malleable incombustible foil such as aluminum foil or the like which has been crimped and compacted to form an undersurface 26. A plurality of vent apertures 24 are defined in upper surface 23.

As is set forth below in greater detail, barbecue enhancer 20 defines an interior cavity within which a compressed and somewhat compacted mixture of aromatic wood material and additional elements are received. The size and number of vent apertures 24 in upper surface 23 is selected to provide the desired combustion rate of aromatic and flavor enhancing materials within enhancer 20. The objective is to provide a slow long duration combustion and outward diffusion of the aromatic and flavor enhancing material within enhancer 20.

FIG. 3 sets forth a section view of barbecue enhancer 20 taken along section lines 3-3 in FIG. 2. As described above, enhancer 20 includes a foil housing 22 having a generally cylindrical shape and defining a cylindrical side surface 25, an upper surface 23 and a crimped undersurface 26. Enhancer 20 further defines an interior cavity 27 within which a quantity of compacted combustible and aromatic mixture 30 is received. As described above, vent apertures 24 extend through upper surface 23 and communicate interior cavity 27 with the exterior of barbecue enhancer 20.

In the configuration shown in FIG. 3, enhancer 20 has yet to commence the above-described combustion process and thus combustible mixture 30 completely fills interior cavity 27.

FIG. 4 sets forth a section view of barbecue enhancer 20 taken along section lines 3-3 in FIG. 2 following the combustion of mixture 30 as barbecue enhancer 20 is utilized in the above-described manner. As can bee seen by comparison of FIGS. 3 and 4, combustible mixture 30 has been reduced to an ash and residue mixture 31 which no longer completely fills interior cavity 27. In accordance with the anticipated use of the present invention barbecue enhancer, enhancer 20 once utilized is allowed to cool and thereafter simply discarded. It should be noted that while foil housing 22 is lightweight and inexpensive to manufacture, it completely encloses both combustible mixture 30 and ash residue 31 during the use of barbecue enhancer 20 and the disposal thereof. As a result, the consumer is able to utilize the present invention barbecue enhancer without the mess and difficulties associated with the refillable prior art devices. In addition, the use of an inexpensive foil housing avoids the substantial expense involved in utilizing prior art disposable containers.

The combustible mixture within the foil housing of the present invention enhancer may be varied in mixture to suit the preferences of the user. It has been found advantageous to utilize a mixture having an aromatic wood such as mesquite or the like together with a spice or spices. In addition, a meat tenderizer may be utilized. Accordingly, it should be understood that in its preferred form, combustible mixture 30 includes a mixture of aromatic wood particles together with a spice combination and a meat tenderizer.

FIG. 5 sets forth a diagrammatic view of a simple apparatus for manufacturing the present invention flavor enhancer. It will be apparent to those skilled in the art that FIG. 5 as well as FIGS. 6A through 6G which follow are intended solely to depict a suggested manufacturing method for the present invention enhancer and that several associated manufacturing components are omitted in the interest of clarity and simplicity. It will be further apparent to those skilled art in the art that such elements are easily and readily obtainable utilizing well known manufacturing apparatus and techniques and thus are not required to be set forth herein.

More specifically, FIG. 5 sets forth a manufacturing apparatus generally referenced by numeral 40. Apparatus 40 includes a generally cylindrical receptacle defining an interior cavity 42 having a slightly tapered side surface 43 and a generally planar bottom 45. Bottom surface 45 further supports a plurality of upwardly extending tapered piercing elements 44 and a center aperture 52. Side surface 43 defines a pair of oppositely positioned apertures 50 and 51. A generally cylindrical piston 55 defines an end surface 56 and is receivable within interior cavity 42 of receptacle 41. A plurality of extendable pins 60, 61 and 62 are supported by a plurality of expander units 70, 71 and 72 respectively. Pins 60 and 61 are positioned within apertures 50 and 51 respectively and are extendable into interior cavity 42 in the directions indicated by arrows 66 and 67 respectively. Similarly, pin 62 is positioned within aperture 52 and is extendable upwardly within interior cavity 42 in the direction indicated by arrow 68. Thus, during the manufacturing process set forth below in greater detail, conventional operative means (not shown) are coupled to piston 55 and provide motion of piston 55 downwardly in the direction of arrow 65 to force piston 55 into interior cavity 42. Similarly, the activation of expanders 70, 71 and 72 provide selective movement of pins 60, 61 and 62 respectively through and out of interior cavity 42 to provide the manufacturing operation set forth below in FIGS. 6A through 6G.

FIG. 6A sets forth a simplified section view of manufacturing apparatus 40 at the commencement of a fabrication cycle. Thus, as described above, apparatus 40 includes a cylindrical receptacle 41 defining a cylindrical interior cavity 42 having a side surface 43 which defines a bottom surface 45 supporting a plurality of upwardly extending piercing elements or points 44. Cylindrical receptacle 41 further defines a plurality of apertures 50 through 52 which receive and support a corresponding plurality of extendable pins 60 through 62 which in turn are coupled to conventional expanders 70 through 72 respectively. A cylindrical piston 55 is coupled to operative means for providing vertical motion therein (not shown) and defines a generally planar end surface 56.

At the initiation of a fabrication cycle, a foil sheet 75 formed of an incombustible preferably malleable material such as conventional aluminum foil or the like generally referenced by numeral 75 is positioned above cylindrical receptacle 41 and beneath piston 55.

FIG. 6B sets forth the initial stroke of piston 55 in which piston 55 has moved downwardly into cylindrical receptacle 41 in the direction indicated by arrow 57 carrying foil sheet downwardly into interior cavity 42 and forcing foil sheet 75 to form about the outer surface of piston 55 to form a cup-like structure. It should be noted that the initial stroke of piston 55 is a partial stroke carrying foil sheet 75 a sufficient distance to form a cup-like depression therein but stopping short of forcing it against bottom surface 45 of receptacle 41.

FIG. 6C sets forth the configuration of apparatus 40 following the initial step of FIG. 6B and the withdrawal of piston 55 from cylindrical receptacle 41. As described above, foil sheet 75 has, as a result, formed a cup-like structure and in accordance with the present invention method, a quantity of combustible mixture 30 has, in the configuration shown in FIG. 6C, been deposited within the cup-like formation of foil sheet 75.

FIG. 6D sets forth the configuration of apparatus 40 following the compacting and compression stroke of piston 55. Piston 55 has again moved downwardly in the direction indicated by arrow 57. In this instance, piston 55 is forced downwardly into interior cavity 52 of receptacle 41 in a full compression stroke driving foil 75 fully to the bottom of cavity 41 and forcing combustible mixture 30 against bottom surface 45 to compact and compress mixture 30. Concurrently, the forcing of mixture 30 against bottom surface 45 also forces the lower portion of foil 75 against piercing elements 44 causing the formation of a plurality of vent apertures (see vent apertures 24 in FIG. 2).

FIG. 6E sets forth the next fabrication step of apparatus 40 in which piston 55 is withdrawn from interior cavity 42 leaving foil 75 and compacted mixture 30 within interior cavity 42. Pins 60 and 61 are forced inwardly in the directions indicated by arrows 66 and 67 respectively to collapse the side portions of foil 75. The character of this collapsing of foil 75 above compacted mixture 30 is adjusted in accordance with the desired crimping to be imposed upon foil 75. Thus, it may be preferable using certain foil materials and thicknesses to provide nonsymmetrical folding of foil 75 by introducing uneven travel extensions of pins 60 and 61. In addition, in the preferred fabrication, pins 60 and 61 are offset to produce a twisting character to the folding operation of FIG. 6E. The important aspect in the manufacturing step shown in FIG. 6E is the desired positioning of the upper portion of foil 75 to provide the desired crimping characteristic imposed thereon in step 6F set forth below.

FIG. 6F sets forth the crimping step of the present invention fabrication method in which pins 60 and 61 are withdrawn from the position shown in FIG. 6F and thereafter piston 55 is again driven downwardly into interior cavity 42. As piston 55 is driven downwardly, end surface 56 folds and crimps the upper portion of foil 75 to form a sealed undersurface 26 (seen in FIGS. 2 through 4). In addition, piston 55 during the crimping step shown in FIG. 6F is able to impose a final compacting force upon mixture 30.

FIG. 6G sets forth the final step in the present invention method of fabrication in which piston 55 is withdrawn from the crimping step shown in FIG. 6F and in which pin 62 is forced upwardly through aperture 52 in the direction of arrow 68 to drive the now completely formed enhancer 20 outwardly from interior cavity 42. This completes the fabrication and apparatus 40 is then ready for the next fabrication cycle by withdrawing pin 62 and returning to the position shown in FIG. 6A.

It will be apparent to those skilled in the art that the manufacturing and fabrication process set forth in FIGS. 6A through 6G provides a low cost and effective manufacture for the present invention barbecue enhancer. The use of a crimped foil enclosure for enhancer 20 avoids the previously encountered expenses and complexity found in the prior art devices. Furthermore, the resulting structure of the present invention barbecue enhancer provides a cost effective, inexpensive and easy to use device which is simply used and discarded. Thus, the present invention barbecue enhancer is virtually free of any attendant mess or residue.

While particular embodiments of the invention have been shown and described, it will be obvious to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects. Therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. 

1. For use in a cooking grill or the like, a disposable enhancer comprising: an incombustible malleable sheet formed into a closed housing defining an interior cavity, a plurality of vent apertures, and a crimped closure surface; and an aromatic combustible particulate mixture received and compacted within said interior cavity.
 2. A disposable enhancer as set forth in claim 1 wherein said closed housing is generally cylindrical.
 3. A disposable enhancer as set forth in claim 2 wherein said housing defines a generally planar upper surface having said vent apertures formed therein.
 4. A disposable enhancer as set forth in claim 3 wherein said housing defines a generally planar undersurface forming said crimped closure surface formed by folding and crimping said sheet about said particulate mixture.
 5. A disposable enhancer as set forth in claim 4 wherein said sheet is aluminum foil.
 6. A disposable enhancer as set forth in claim 1 wherein said particulate mixture includes wood particles.
 7. A disposable enhancer as set forth in claim 6 wherein said particulate mixture includes spice additives.
 8. A disposable enhancer as set forth in claim 7 wherein said particulate mixture includes a meat tenderizer.
 9. For use in fabricating a disposable enhancer having a combustible particulate mixture within a foil housing, the method comprising the steps of: positioning a malleable incombustible planar foil sheet; forming a depression in said sheet; depositing a quantity of combustible aromatic particulate material into said depression; compacting said particulate material; folding and crimping said sheet to enclose said particulate mixture; compressing said folded and crimped sheet and particulate mixture to form a foil housing enclosing said particulate mixture; and forming a plurality of vent apertures in said sheet.
 10. The method of claim 9 wherein said step of depositing includes the steps of: forming a plurality of wood particles; adding at least one spice to said wood particles; and mixing to a generally uniform particulate mixture.
 11. The method of claim 10 wherein said depositing step further includes adding a meat tenderizing material.
 12. The method of claim 9 wherein said step of depositing includes forming a plurality of wood particles.
 13. The method of claim 12 wherein said forming step includes the steps of: forcing said sheet at least partially into a cylindrical cavity using a generally cylindrical piston; and withdrawing said piston. 